Shipping and dispensing container

ABSTRACT

A COMPOSITE SHIPPING AND DISPENSING PACKAGE IS DISCLOSED WHICH INCLUDES AN OUTER CONTAINER HAVING A NOVEL, INTEGRAL LOWER END CONFIGURATION FOR ACCOMMODATING INDUSTRIAL TRUCK HANDLING DEVICES WITHOUT THE NEED FOR AUXILIARY PALLET STRUCTURES. THE PACKAGE ALSO INCLUDES A NOVEL INNER CONTAINER CONSTRUCTION TO INSURE COMPLETE AND UNRESTRICTED UNLOADING THROUGH AN INSTANT DISPENSING BOTTOM CLOSURE.

Sept. 21,1971

J. VOYTKO SHIPPING AND DISPENSING CONTAINER 3 Sheets-Sheet 1 Filed Jan. 26, 1970 k v l i If n v 1 I 1? i /3 E f niflfi INVENTOR Joseph Voyfka ATTORNEY Sept. 21', 1971 J.';VOYTKO SHIPPING AND DISPENSING CONTAINER 3 Sheets-Sheet 2 Filed Jan. 26, 1970 R 00 WW h 0. e w J BY AM? 6 ATTORNEY p 9 J. VOYTKO 3,606,969

, SHIPPING AND DISPENSING CONTAINER Filed Jan. '-26, 1970 3 Sheets-Sheet 5 I INVENTOR Joseph VoyI/ro ATTORNEY United States Patent 3,606,969 SHIPPING AND DISPENSING CONTAINER Joseph Voytko, Lakewood, Ohio, assignor to Westvaco Corporation, New York, NY. Filed Jan. 26, 1970, Ser. No. 5,588 Int. Cl. B65d 19/20 US. Cl. 229-37E 21 Claims ABSTRACT OF THE DISCLOSURE A composite shipping and dispensing package is disclosed which includes an outer container having a novel, integral lower end configuration for accommodating industrial truck handling devices Without the need for auxiliary pallet structures. The package also includes a novel inner container construction to insure complete and unrestricted unloading through an instant dispensing bottom closure.

SUMMARY OF INVENTION This invention relates to relatively large packages for storing and shipping large quantities of bulk commodities. In one aspect, the invention relates to a pallet-less container wherein a pallet-like structure is an inherent part of the container design. In another aspect, the invention relates to an expendable, pallet-less container for the storage and shipment of bulk material while featuring an instant dispensing lower end construction. Still another feature of this invention resides in the novel design of a bulk container and its application to handling by forklift trucks without the necessity of providing other elements to accommodate the forklift truck tines.

The package of this invention was developed primarily as a dispensing container for materials stored in bulk form, and as such, the design required several elements for its construction. Initially, a pallet-less outer container structure was fabricated, then a pair of inner containers were added to form two compartments which added strength and integrity to the outer container, and also insured a smooth, uninterrupted dispensing operation. This is the preferred form of the invention and represents the embodiment illustrated and described in detail. The novel container of the invention could, of course, be fabricated differently for packaging different commodities and the detail changes necessary for such other uses are deemed to be inherent in the concepts and descriptions set forth herein.

Improvements in fibreboard and corrugated paperboard containers have made possible the use of such containers for handling, storing and transporting relatively large quantities of bulk materials, such as granular chemicals, grains and the like. The unusual strength and resiliency of the materials employed permit the use of packages carrying quantities of from 500 to 2000 pounds and more. Furthermore, with certain arrangements of the container construction and bottom cap closure, it is possible to provide a heavy-duty container which does not permit leakage of the granular or other bulk product, but which does insure dispensing of the contents with a smooth anduninterrupted fiow. While it is a comparatively easy matter to load the relatively large containers through a top opening, the unloading of the containers often presents considerable problems. It is expensive and time consuming to unload the containers through the top opening, and, due to the great weights involved, it is nearly impossible to up-end the container to discharge the contents. Hence dispensing through the bottom of the container appears to be the only feasible way of handling the often considerable quantities of stored products.

Bottom dispensing containers on the other hand, must be picked up to be emptied, and generally containers of they are used, however, so that during shipping or storage of the packages and pallets, maximum use is not made of the available space. Furthermore, projecting edges of the pallets are subject to breakage during loading and unloading. Standard wood frame pallets are heavy and relatively expensive, and not well adapted to the growing air cargo industry. If the containers are not shipped with the pallets, loading unloading of the containers onto or off the pallet is necessary at shipping points before forklift truc-k transport is possible.

It is therefore, an object of this invention to provide in a new and improved package, a novel pallet-less lower end construction integrally formed therewith to provide maximum use of the available space and permit ease of handling.

Moreover, it is an object of this invention to provide in a pallet-less bulk carrying container, a novel instant dispensing means at the lower end thereof.

In addition, the invention contemplates a package having the utility of being adapted to be easily handled, stored or dumped from the platform tines of a forklift truck.

Another object of the invention is to provide a new and improved lightweight and inexpensive yet strong container particularly suited for construction from cor-' rugated paperboard or other suitable material.

A further object of this invention is the provision of a substantially rigid, and at the same time expendable container for handling bulk material.

DESCRIPTION OF DRAWING FIG. 1 shows in plan a typical blank structure for forming the outer container construction;

FIG. 2 shows in plan an example of the blank structure for constructing the inner container element;

FIG. 3 illustrates in perspective the outer container in partially completed form;

FIG. 4 shows in perspective the partially completed inner container formed from the blank of FIG. 2;

FIG. 5 illustrates in perspective a composite view of the different elements of the invention completely formed and in an intermediate stage of assembly;

FIG. 6 shows the completed container, filled and banded for shipping; and,

FIG. 7 illustrates the container in its dispensing mode from the industrial lift truck.

BRIEF DESCRIPTION OF INVENTION The novel bulk dispensing package of this invention comprises in its preferred form an outer container structure which has a stepped and reinforced lower end for accepting without additional elements the tines of a forklift truck. The construction thus eliminates the need for a pallet for storage and transport and thus takes up less space and is cheaper than a palleted container, or a container plus a pallet. On the inside of the outer container, there is arranged one or more, and preferably two, inner compartments with tapered side walls in the vicinity of the outer container stepped areas to insure free and uninterrupted flow and a complete discharge of the packaged commodity from the container. The lower end of the outer container is made up of a series of closure and reinforcing panels and flaps which may be secured together, but preferably are not so secured to permit the container to function with its instant lower end dispensing feature. The open lower end of the outer container is temporarily capped with a closure means having one wall thereof partially secured to an outer container wall to allow the closure cap to function as a flap valve during dispensing. The upper end of the outer container is also capped after loading of the inner compartments and the entire structure is banded to provide an integrated structure during storage and handling. Banding is applied around the periphery of the container first, then the lower end closure cap is banded to hold it in place.

The package thus defined is suitable for the transport and storage of bulk type commodities and is subject to being dispensed on demand. In addition, the novel container described herein is readily handled for either transport or dispensing by a forklift truck without the need for additional elements.

DETAILED DESCRIPTION The outer container of the package embodied in the present invention may be constructed from a single blank of material which is suitably cut and scored, or it may be fabricated from two half blanks which are initially secured together. In the original form, it was necessary to use two half blanks because of the size of the container being manufactured. The facilities available for building the first sample containers were limited to a sheet of 64 by 100 inches and the customer wanted a larger container. The order was accommodated however, by using two blanks and stitching them together.

It is noted, on the other hand, that the drawing shows an outer container blank in FIG. 1 which is cut from a single sheet of material. The blank typically comprises four rectangular side walls 10, 12, 14 and 16, separated from one another by fold lines 11, 13 and 15. Attached to side wall along fold line 17, is a closure flap 18 which is used to hold the outer container together. This closure flap 18 may, of course, be secured in any particular fashion to the opposite side wall 16, but the preferred method is stapling. This connection must be very strong to withstand the loads and forces involved in the larger containers filled with bulk products.

Each side wall 10, 12, 14 and 16 has attached to its extreme upper edge suitable closure flaps 20, 22, 24, and 26 along fold lines 12, 21, 23 and 25 respectively. Depending upon the material to be carried by the container, these top closure flaps may take varying sizes. Generally, however, the top of the outer container is closed off by a cap structure and the flaps may accordingly be small or even omitted entirely.

The closure panels at the bottom of each side wall 10, 12,14 and 16 must be carefully cut and scored to form the desirable shelf structure which accommodates the forklift truck tines. Note that the panel structures for side walls 10 and 14 are identical, and the panel structures for side walls 12 and 16 are identical. These panels may be cut the same since they form the respective opposite sides of the bottom closure of the outer container. The panels at the bottom of side walls 10 and 14 each comprise a pair of reinforcing flaps 29, 30 attached to the stepped side edges of walls 10 and 14 along fold lines 33, 34 respectively. Intermediate these flaps 29, 30 and separated therefrom by cut lines 31, 32 are bottom closure flaps 28 attached to side walls 10 and 14 by fold lines 27. The fold lines 27 are offset below the fold lines 33, 34 so that the side walls 10 and 14 may extend lower than the side walls 12 and 16 when the container is set-up. This extra length provides the base for the outer container and leaves a space at each side for the forklift truck tines. The closure flaps at the bottom of side walls 12 and 16 each comprise three panels 35, 38 and 40 of unequal width, and separated from the side walls by fold line 36 and separated from one another along fold lines 37, 39. These panels are scored so as to form a stairstep configuration and thus define the ultimate faces which come in contact with the forklift truck tines. When folded during assembly, the panels form a first pair of shelf panels 35, an intermediate pair of shelf panels 38 and a pair of shelf flaps 40.

The set-up outer container blank is operated on initially by pre-breaking all score lines and then the blank is turned upside down so that the lower end can be erected. If two outer container blanks are used, the two are secured together as by stapling as suggested hereinbefore. The erected outer container is formed as illustrated in FIG. 3 by folding the main side walls 10, 12, 14 and 16 about the hinge connections 11, 13 and 15 to construct a tubular shell with the connecting flap 18 being secured to the then adjacent free side edge of wall 16 using adhesive, tape, staples or other conventional means. Opposed reinforcing flaps 29, 30 attached to the stepped side edges of side walls 10 and 14 are folded about fold lines 33, 34 preparatory to forming the shelves which accept the forklift truck tines. The bottom construction of the outer container is continued by folding shelf panels 35 in about fold lines 36 to assume a position adjacent and below the reinforcing flaps 29, 30. The intermediate shelf panels 38 are then folded down and away from the reinforcing flaps 29, 30 to permit manipulation of bottom closure flaps 28 attached to walls 10, 14. Bottom closure flaps 28 are next folded in about fold lines 27 to partially close off the lower end of the container. Finally, the shelf flaps 40 are then folded up and under about fold lines 39 to lie adjacent the bottom closure flaps 28. FIG. 3 illustrates the folding operation described above in an intermediate position. Note that in the preferred embodiment the sequence for folding the bottom flaps is, first, reinforcing flaps 29, 30 then bottom closure flaps 28, and finally the pre-formed stepped flaps 35, 38 and 40. This sequence could be varied to suit the construction desired and is not deemed to be limiting. Moreover, if it was found possible, one or more of the flaps could be eliminated, depending on the commodity packaged and the strength needed in the container. However, using the sequence of folding set out above yields an outer container having fairly stiif side walls secured together, but with the bottom closure panels unattached and simply folded into position.

It is to be understood that the bottom closure flaps and panels could be made larger so as to overlap one another and be secured together. However the preferred container described herein is directed primarily to a bulk dispensing package which requires that the bottom be left free to assume an unrestricted opening for the dumping of the bulk product stored therein. For a closed container, the reinforcing panels 29, 30 would be secured to the shelf forming panels 35 to form a more or less rigid pallet-less structure. As a practical matter, these panels could be secured to one another in the bulk dispensing container form as long as the flap elements 40 Were not too long and would not restrict the free movement of the bottom closure flaps 28. Of course, in the closed bottom container, it would be necessary to provide the bottom closure flaps 28 with a dimension to completely cover the bottom and preferably overlap one another. Also the bottom closure flaps 28 would have to be secured, as by stapling or gluing, to the final flap elements 40.

However, referring back to the container structure for bulk dispensing as described above, with the outer container shell still upside down, the bottom is then secured and closed off by a cap member 80. FIG. 5 shows a composite view of the dispensing container in an intermediate stage of assembly. The outer container is illustrated as being completely assembled and ready to accommodate a pair of inner containers. A completed top cap and a completed bottom cap are also shown prior to being assembled.

Top cap 70 is formed in conventional fashion from a blank of material having four side walls 71 of similar dimensions which are held together at their adjacent edges by tape 72 or the like. The cap 70 fits closely around the side walls of the outer container.

Bottom cap 80 includes three side walls 82 of substantially the same dimensions and a fourth side wall 81 which is larger than the side walls 82. The fourth side wall 81 is made larger so as to extend a distance up onto a side wall (as for instance, side wall 14) of the outer container. Note the view in FIG. 6. In that illustration, side wall 81 projects above the stepped lower end construction and is fixedly attached to the outer container side wall 14 to form the flap-type lower end opening means. The bottom closure cap fits snugly around the lower part of side walls and 14 and in contact with intermediate shelf panels 38 and acts as a flap valve during the dumping operation. Cap structure 80 comprises a simple slotted blank construction with four side walls 82, 81 which are taped 83 or otherwise secured to one another to form a tray-like structure. The edge or side wall 81 of the closure cap 80 that is fixedly secured to the side wall face 14 is substantially wider than the remaining closure cap side walls 82 to achieve the desired results. After the bottom closure cap is fitted in place and the larger edge thereof is attached as described, the entire structure is banded 75 to hold the caps 70 and 80 snugly in place prior to dispensing. Of course, the outside of the container is then marked to identify the free side of the bottom closure cap and the hinged side as shown in FIGS. 6 and 7.

The outer container construction described above yields a container having stepped edges at the lower end thereof adjacent the areas where the worklift tines are accepted, and these edges provide a space at each side of the container which could trap bulk material stored therein. To counteract this possibility, a single inner container, or as shown, a pair of inner containers have been provided with angularly oriented side walls in the vicinity of the stepped edges to insure continuous and smooth flow of the bulk material during dispensing.

An example of one inner container is shown in blank form in FIG. 2. The container or liner typically comprises four side walls 50, '52, 54 and 56 separated from one another along fold lines 51, 53 and 55. One of the side panels 54 extends only part of the way from the top edge of the inner container so that the lower portion thereof at 68 can assume the angular orientation for the purpose hereinbefore described. Each of the inner container side panels 50 and 54'has a dimension equal to the side walls 12 or 16 of the outer container while the side panels 52 and 56 of the inner container are each one-half the width of the outer container side walls 10 or 14. This arrangement permits the use of two inner containers forming a pair of compartments wherein one panel of each inner container has the angulated panel. This construction is illustrated in composite FIG. 5. Of course, these inner containers not only provide a smooth flow of the bulk material during dumping, but they also give the entire package additional strength.

The inner container is assembled as shown in FIG. 4 without stitching or stapling except for securing side wall 50 to side wall 56. Typically tape 67 is used to perform this attachment. Each of the scores is pre-bent for ease of assembly and to permit the formation of the tapered side wall construction. After the side walls 50 and 56 are taped together, small tabs 72 are folded in along fold lines 71 and panel 68 is urged in toward the center of the container. This step is accomplished by making reverse folds along fold lines 65 and 6-6 to align triangular panels 64 adjacent the side walls 52 and 56. Bottom closure flaps 58 and 70 are then folded closed to be overlapped by second closure panels 60. Finally, the reinforcing flaps 62 are folded in about fold lines 63 to ultimately rest on the shelf panels 35 of the outer container.

As pointed out hereinbefore, the bulk container described herein is designed to accommodate a pair of inner containers to form two interior compartments. Hence, after constructing two of the inner containers, the entire container is further assembled by telescoping the two inner compartments into the outer compartment. Since the bottom closure cap has been previously secured in position, the container is then ready to be filled. After filling, the top closure cap 70 is applied to the container and it is suitably strapped 75, 76 to form an integrated structure. With the container properly marked to indicate which side of the lower valve type closure cap is secured to a side wall, the container can readily be approached and picked up by a forklift truck for dumping on site. FIG. 7 shows an example of how the container can be handled by a forklift truck for dispensing on site. After the container is picked up as shown, it is then transported to the point for dispensing and the bands are cut to allow the bulk material to flow out. It has been found that the normal gravitational flow is enough to completely empty the con tainer.

Thus the herein described container not only features the novel dispensing feature, but it also eliminates the need for any form of pallet structure. Of course, most prior art bulk packs are strapped to a pallet of some type for ease of transporting.

In plant tests were conducted on the container structure described herein to determine the capabilities and performance of the package regarding storage, ease of transporting and any bulging or rupturing effects occurring during storage and handling. The storage test comprised filling the container to the top with sand, then banding as described. Next the container was set aside for three weeks with a dead weight of approximately 2000 pounds placed on top. Periodic checks were made to investigate bulging and/or ruptures, but no problems occurred. The bulge that did take place was minimal being approximately /2 to inch. Finally, the filled container was picked up by a forklift truck and transported throughout the plant to investigate the handling properties. No damage occurred because of the presence of the forks.

In the use of the combination shipping and dispensing package of the present invention, it is contemplated that the package would be shipped to its destination and during shipping it could be readily handled by conventional forklift trucks or other article handling equipment by virtue of its unique lower end construction. After reaching its destination it could then be dispensed as shown in FIG. 7 into a bin or other storage area, or, simply on site for ultimate use. Furthermore, it should be clear that the different panels and flaps of the package could be folded with different sequences to accommodate different loads within the scope of the invention described. Finally, it should be apparent that the composite container described could be adapted for custom design to suit particular packaging and container needs.

Thus other adaptations and modifications could be made without departing from the true scope and spirit of the invention as claimed. I

I claim:

1. A composite pallet-less shipping and dispensing package for the transport of materials by forklift truck comprising:

(a) a tubular outer container having a plurality of side walls connected together along fold lines to form an upstanding body portion, said side walls including a first pair of opposed walls of rectangular configuration, and a second pair of opposed walls with stepped side edges;

(b) a plurality of bottom closure panels foldably atached to the lower ends of said outer container side walls forming a stepped and reinforced lower end;

(0) a tubular inner container having side walls which fit inside of and lie adjacent to the side walls of said outer container, and including bottom closure panels foldably attached to the lower end thereof; and,

(d) means attached to the lower end of said outer container for dispensing the material stored in the package.

2. The shipping and dispensing package of claim 1 wherein the bottom closure panels attached to the first pair of opposed side walls each further comprise:

, (a) first shelf panels foldably attached to the respective side walls;

(b) intermediate shelf panels foldably attached along the free edges of said first shelf panels; and,

(c) shelf flaps foldably attached along the free edges of said intermediate shelf panels.

3. The shipping and dispensing package of claim 2 wherein said first shelf panels, intermediate panels and shelf flaps are each of the same length as the first side walls and when folded form the stepped lower end construction for accepting the forklift truck tines.

4. The shipping and dispensing package of claim 3 wherein the bottom closure panels attached to the second pair of opposed side Walls each further comprise:

(a) bottom closure flaps foldably attached to the extreme lower end of the respective side walls; and,

(b) pairs of reinforcing flaps foldably attached to the stepped side edges of each of said side walls.

5., The shipping and dispensing package of claim 4 wherein each of said reinforcing flaps has a length equal to the combined width of a bottom closure flap and the height of the step at the side edges of the second pair of side walls.

6. The shipping and dispensing package of claim 5 wherein each of said reinforcing flaps has a width approximately equal to the width of a first shelf panel.

7. The shipping and dispensing package of claim 6 wherein the intermediate panels have a width substantially equal to the height of the step at the side edges of the second pair of side walls.

8. The shipping and dispensing package of claim 7 wherein the outer container is constructed by:

(a) folding the side walls about their connecting fold lines to form the body portion;

(b) folding the reinforcing flaps into the plane of the stepped side structure;

(c) folding the first shelf panels into a position adjacent and below'said reinforcing flaps;

(d) folding the intermediate flaps down and away from the reinforcing flaps;

(e) folding the bottom closure flaps into the plane of the bottom structure; and,

(f) folding the shelf flaps up and under adjacent the bottom closure flaps.

9. The shipping and dispensing package of claim 7 wherein the inner container side walls further comprise:

(a) a first pair of panels having a width dimension equal to the width of the second pair of opposed side walls of the outer container and a height dimension equal to the total height of said second pair of opposed side walls; and,

(b) a second pair of panels having a width dimension and a height dimension equal to the width and height of the first pair of opposed side Walls of said outer container.

10. The shipping and dispensing package of claim 9 wherein the said first pair of panels each comprise:

(a) a rectangularly shaped upper portion separated from an angularly oriented lower portion by a fold line, said angularly oriented lower portion providing a continuous inner wall in the region of the stepped area of said outer container lower end.

11. The shipping and dispensing package of claim 10 wherein the said second pair of panels each have extreme lower ends with stepped side edges to accommodate the angularly oriented lower portions of said first pair of panels.

12. The shipping and dispensing package of claim 11 wherein the said inner container panels are each joined together by fold lines along the upper portion of the first 8 and second pairs of panels, and by triangular panels along the lower portion of said first and second pairs of panels.

13. The shipping and dispensing package of claim 12 wherein the said inner container is formed by:

(a) folding the side wall panels about their connecting foFd lines to form a body portion; and,

(b) reverse folding the triangular panels about their connecting fold lines to form the angularly oriented lower portion.

14. The shipping and dispensing package of claim 13 wherein said formed inner and outer containers are telescoped together and a bottom closure cap is fitted to the stepped lower end of said outer container.

15. The shipping and dispensing package of claim 14 wherein one edge of said bottom closure cap is fixedly secured to an adjacent wall of said outer container to form the dispensing means of said package.

16. The shipping and dispensing package of claim 15 wherein a top closure cap is fitted to the upper end of said outer container after said package is filled.

17. The shipping and dispensing package of claim 16 which includes bands around the periphery of said outer container side wall, bottom closure cap and top closure cap to retain the integrity of said package during transport.

18. The shipping and dispensing package of claim 17 which is automatically dispensed by gravitational flow upon the cutting of said bands.

19. A composite pallet-less shipping and dispensing package for the transport of materials by forklift truck comprising:

(a) a tubular container having a plurality of side walls connected together along fold lines to form an upstanding body portion, said side walls including a first pair of opposed walls of rectangular configuration, and a second pair of opposed walls with stepped side edges; and,

(b) a plurality of bottom closure panels foldably attached to the lower ends of said outer container side walls forming a stepped and reinforced lower end to accept the tines of a forklift truck, said bottom closure panels including;

(1) first shelf panels foldably attached to the first pair of opposed side walls;

(2) intermediate shelf panels foldably attached along the free edges of said first shelf panels; and,

(3) shelf flaps foldably attached along the free edges of said intermediate shelf panels.

20. The shipping and dispensing package of claim 19 wherein said bottom closure panels further include:

(4) bottom closure flaps foldably attached to the extreme lower ends of said second pair of opposed side walls; and,

(5) pairs of reinforcing flaps foldably attached to the stepped side edges of each of said second pair of 0pposed side walls.

21. A composite pallet-less shipping and dispensing package for the transport of materials by forklift truck comprising:

(a) a tubular outer container having a plurality of side walls connected together along fold lines to form an upstanding body portion, said side walls including a first pair of opposed walls of rectangular configuration, and a second pair of opposed walls with stepped side edges;

(b) a plurality of bottom closure panels foldably attached to the lower ends of said outer container side walls forming a stepped and reinforced lower end;

(c) a pair of tubular inner containers having upper side walls which fit inside of and lie adjacent to the side walls of said outer container, and lower side Walls which provide an angulated, continuous inner wall in the region of the stepped area of said outer container; and,

(d) means attached to the lower end of said outer con- 9 10 tainer for dispensing the material stored in the 3,199,764 8/1965 Oliver 229-37E 1 package, 3,261,532 7/1966 Davis 22937R References cued DONALD F. NORTON, Primary Examiner UNITED STATES PATENTS 5 2488194 11/1949 H unsworth 22923B 2 ,894,666 7/1959 Campbell 2297RX 222176;2297R, 1713,2311, 116R 

